Structural Insulated Header for Architectural Features

ABSTRACT

The present invention relates to the construction arts, in particular a modular implementation for a structural support member or header for bearing the load of large spans of a floor, wall section above a window, door or entry way. The header is modular and can be easily implemented into a variety of architectural structures. A façade can be formed which easily allows complex arches to be created such as round, horseshoe, lancet, ogee, trefoil and so on. The support member can also include an insulation which, when used with a steel beam, serves to increase the insulation value.

RELATED APPLICATIONS

The present application is a continuation-in-part application of U.S.Utility patent application Ser. No. 12/122,822; filed 17 May 2007, nowabandoned which claims priority form provisional patent application Ser.No. 60/938,512; filed 17 May 2007, included by reference herein and forwhich benefit of the priority date is hereby claimed.

FIELD OF THE INVENTION

The present invention relates to static structures used in theconstruction arts. In particular a header partition support for use withjoists, trusses, windows and doors which is; modularized, insulated andallows ease of construction and attachment surfaces.

BACKGROUND OF THE INVENTION

In construction, it is important to bear high structural loads in orderto support a building or other similar structure. Typically this hasbeen done by providing a structure framed with 2×4 inch or 2×6 inch etc.cross-sectional studs provided with a regular spacing to support theweight. When a window or door is desired in the structure, that spacingis disrupted and the stresses can become concentrated to the point wherethe integrity of the larger structure is compromised. In an attempt toaddress this issue, a lateral support member, commonly called a header,is placed above the opening to bear the weight otherwise carried by thestuds, and transfer the load to the outer perimeter of the openingallowing the opening to bear the load.

Further when a mid-span support is required for a floor intersection, abeam or header structure can be used to support the trusses or joists.Many times this is support structure is realized by resting the joistsor trusses on the beam creating a separate level of structure, which canbe unsightly as seen from the floor below.

Prior art for constructing window and door headers can be as simple astwo lateral beams, typically 233 8 to 2×12 inches in cross-section,nailed together with a piece of plywood sandwiched in between, to setthe proper spacing, and placed laterally above the opening to transferthe load to a pair of king studs located vertically at the perimeter ofthe opening. This solution typically does not have good insulation valueand the beam and plywood members can twist and warp and deflect due toload.

In additional alternative a glued laminated timber, or glulam can beused to replace the solid beam. This provides a nailing surface forhanging sheetrock, or other facing, and some structural support but hasbeen plagued by structural fatigue due to delamination over time, andthe structural limits of wood's load bearing capacity.

Recently, steel “I” beams have been used, which are superior to wood forload bearing capability, but one problem being no sufficient structurefor nailing or otherwise attaching other items to the beam. Due to theincompatibility of steel beams for attaching, the structure to besupported is rested on top of the beam, which creates architecturalchallenges as mentioned above. Another issue being the very poorinsulation quality of steel without other means for mitigation.

SUMMARY OF THE INVENTION

The current invention, comprises an enclosed structure to provide apre-formed modularized insulated beam for forming lintel or headerstructures. This apparatus and methodology, when combined with astructural metal beam such as an “I” beam, complements and evenstrengthens the load bearing capacity of the beam. Those skilled in theart can appreciate that an “I” beam can comprise an S beam (standardbeam) and a W beam (wide flanged beam). The apparatus can furtherprovide a suitable attachment surface during subsequent constructionoperations such as nailing, screwing, gluing and the like. In additionto provide adequate insulation value for the metal beam, which isnormally a poor thermal insulator, which is extremely important incolder climates.

BRIEF DESCRIPTION OF THE DRAWINGS

A complete understanding of the present invention may be obtained byreference to the accompanying drawings, when considered in conjunctionwith the subsequent, detailed description, in which:

FIG. 1 depicts a perspective view of a structural header;

FIG. 2 depicts a side plan view of a structural header;

FIG. 3 an exploded view of a structural header;

FIGS. 4A through 4F depict partial side plan views detailing structuralconsiderations for alternate embodiments of a structural header;

FIG. 5 depicts a perspective view of a structural framing for a windowusing a header of the present invention;

FIG. 6 depicts a top perspective view of a header in construction withjoists and nailers;

FIG. 7 depicts a perspective view of a header in construction withtrusses forming a floor above an opening for large panel doors and thelike;

FIG. 8A depicts a perspective view of a curved arch structure with loadbearing capabilities which incorporates the header;

FIG. 8B depicts a perspective view of a polygon arch structure with loadbearing capabilities which incorporates the header;

FIG. 8C depicts a perspective view of an ogee arch structure with loadbearing capabilities which incorporates the header;

FIG. 9A depicts a side plan view of an alternate embodiment of astructural header;

FIG. 9B depicts an exploded view of an alternate embodiment of astructural header.

FIG. 9C depicts a side plan view of a structural header with a joisthanger and joist attached to the face.

DETAILED DESCRIPTION

The structural header as shown in FIGS. 1, 2A, 2B, and 3; consistingprimarily of a beam 10, one embodiment of which FIG. 2A is an example,comprising a pre-manufactured box beam 10 a comprising a pair ofhorizontal members 16 connected with a pair of vertical members 18 withan insulation space 14 generally comprised of structural foam.

In another embodiment shown in FIG. 2B an element known in the trade asan “I” beam is added to the system. The beam 12, which is typically madeof a metal such as steel, and is comprised of a web portion 11 which isa vertical member for load bearing, being nominally 8 to 12 inched inheight, and two flange portions 13 located on the top and bottom of theweb portion 11, being nominally 4 inches in width, for lateralstability. While the beam 12 is typically quite strong compared withwooden framing for construction purposes, it does not provide goodnailing or attaching surfaces typically required in conjunction withwooden framing. Additionally it is a poor insulator. To help utilize the“I” beam 12 for general construction purposes, a box is created aroundthe beam 12 in such a way as to strengthen it from twisting andtorquing, by adding a structural horizontal member 16 which is typicallyglued or otherwise affixed to the flange portions 13 of the beam. Thehorizontal member 16 is preferred to extend beyond the flange portions13 sufficient to provide a fastening surface for the vertical members18. The vertical members 18 can be affixed to the horizontal framingmembers through fasteners 22 which can be any combination of screws,nails, glue, tape, staples, or the like. With a preferred embodimentbeing screws, such as drywall screws generally of 1½ to 2 inches inlength. In addition the framing members can be wood, oriented strandboard (osb), plywood, hardboard, or other suitable material of suitablethickness with ¾ inch being most common.

To further enhance the properties of the structural header 10, aninsulation space 14 is provided for supplying insulation. Thisinsulation space 14 can be filled with any combination of; rock wool,fiberglass, Styrofoam, or polyurethane foam, or their equivalents. Withthe preferred method being an open cell, low density, non-ozonedepleting polyurethane foam which is not subject to deterioration frommoisture. The foam can be added through injection points 15 providedalong the vertical member 18 in the region of the insulation space 14and further expands to fill the insulation space 14 with the advantageof further securing, by adhering to or gluing, the beam 12 and the frame17. To keep a polyurethane foam from expanding out the lateral openingof the insulation space, a form or board can be temporarily affixed tothe ends of the structural header 10 until the foam sets up.

Lateral support for fastening to a structure is added by including anailer 20, shown in FIGS. 1 and 3 to connect the end of the structuralheader and tie into the studs. The nailer 20 is typically a plate orjoist nailer which may be folded back until needed in construction.

Several functional alternate embodiments for construction of thestructural header are shown in FIGS. 4A through 4F. These Figures showapproximately the top half of a partial side plan view of a structuralheader similar to that shown in FIG. 2 as the structure will typicallycomprise a top to bottom symmetry. While those skilled in the art may beable to devise alternate structures for enclosing the beam 12, it isclaimed that these are within the scope of this invention.

As the insulation space 14 is filled with expanding foam insulation,forces are created inside the insulation space 14 which can berepresented by a vertical vector component A and a horizontal vectorcomponent B. FIG. 4A shows a construction where the horizontal member 16forms a butt joint with the vertical member 18. In this case thehorizontal vector component B has only the fastener 22, which isfastened into the horizontal member 16 to act against the horizontalvector component B. This may result in the fastener 22 pulling outresulting in separation between the vertical member 18 and the beamresulting in insulation foam expanding out of the insulation space 14and further structural weakening of the structural header 10. Therefore,while possible to implement, this mode is not preferred to one with amode which secures the joint against expansion.

FIGS. 4B through 4F show several alternate modes which overcomedisadvantages seen in embodiment of 4A. These embodiments derive fromthe property of the flange portion 13 of the beam 12 to deflect theforces, particularly the vertical vector component A, created by theexpansion of foam insulation. In particular the vertical vectorcomponent A. FIG. 4B shows an embodiment in which the vertical member 18is butt jointed to the horizontal member 16 requiring the fastener 22 tobe sheared before separation could occur through action by thehorizontal vector component B. FIGS. 4C through 4E show alternate modesfor providing enclosures for the structural header to include: dados,rabbets, lock joints, spline joints, tongue and groove, mortise andtenon and the like. FIG. 4F shows a preferred mode of providing ahorizontal double nailer 16 a being generally 1½ inch thick having arabbet for providing double nailing and attachment surfaces.

Examples of the structural header 10 for use in the construction artsare shown in FIGS. 5, 6, 7 and 8. The structural header 10 can be usedin framing above windows, doors, garage door openings and the like. Itis used to deflect the load in a bearing wall, generally through a topplate 32 which comes from a roof, other floors of the structure, and thelike; and to transfer the load to the foundation through the sill plate30. These loads would typically be borne by studs 34 in a continuouswall. This load transfer is typically done by deflecting the load alongthe structural header 10 to a structural support such as a king stud 36which directly bears the load.

In some instances, a simple header of “two by” construction may besufficient to deflect the load. But increasingly with architecturaldemands, the structural header, or lentil, of prior art is inadequate tosupport the span. Large spans, such as garage door openings, platewindows or large door frames, decks, arched entries, extra floors, allhaving large expansive openings require additional reinforcement. Oneexample of the utility of the current invention can be seen byconsidering the structure exemplified in FIG. 6. In the prior art (notshown), a structure similar to that shown in FIG. 6 would have beenaccomplished by running a steel beam under the joists 42 as a steel beamcannot be nailed into to secure wooden structures. A steel beam underthe joists causes unsightly seams and depressions as seen from the floorbelow. Further carpenters expend considerable work to try and blend in abeam for architectural reasons. The structural header 10 of the currentinvention provides both the structural support of a beam 12 with theability to attach joists 42 at the floor level with a standard joisthanger 40, while providing insulation space 14. In another example shownin FIG. 7, a structural header 10 is used to tie into and support thatload from truss members 44 above a large opening where the load isdeflected to king studs 36 for the area below the opening. The king stud36 for the purposes of this disclosure may be made of wood, metal, orother suitable load bearing material. The ability to provide structuralsupport having an architecturally pleasing structure, with surfaces fornailing, insulation and other advantages is provided.

In FIGS. 8A, 8B and 8C, a modular arch unit 46 is created having ahorizontal double member 16 a with a beam 12 wherein vertical members 18a, 18 b, 18 c respectively in the form of a façade replaces the verticalmember 18 such that an architecturally pleasing arch is created. Thevertical members 18 a, 18 b, and 18 c extend beyond the secondhorizontal member shown as 52 in dashed lines in the drawings. Themodular architectural façade requiring little skill on the part ofconstruction workers to add it to an existing framing structure, asthose with skill in the art can appreciate. Types of architecturalarches that can be created; include curved, polygon, round, horseshoe,lancet, ogee, trefoil, basket handle, Tudor and the like. Curved 8A,polygon 8B, and ogee 8C have been chosen for illustration purposes. Anogee is characterized by a compound curve having one or more points ofinflection. Another common description being an “S” curve particularlypointed arch having a reversed curve on either side of the apex. A Tudorarch being defined generally as a 4 centered pointed arch. A lancet archcan be defined as a relatively narrow arch with an acutely pointed apex.Trefoil can be defines as stylized interpretation of a clover leaf. Itcan be seen by those skilled in the art that many pleasing designsincluding these and others can be easily achieved while forming astructural header module.

FIGS. 9A and 9B represent an embodiment to the structural header 10comprising a cleat 19, thus forming an alternate vertical member 18 a.The cleat 19 can be any, cleat, shelf, projection, ledge, sill, step,ridge or other solid structural rigid overhang or member designed toreinforce a vertical member 18 (not shown) providing strength or hold inposition. The cleat 19 can also be integrally formed along the entireelongated edge as part of the vertical member 18 as shown in FIGS. 9Aand 9B. The cleat 19 can be advantageous in cases where a joist hangeris nailed to the side of the alternate vertical member 18 a, as shown inFIG. 9C. The cleat 19 utilizes the flanges 13 of the beam 12 to furthersupport the alternate vertical member 18 a.

CONCLUSION, RAMIFICATIONS, AND SCOPE

Although the present invention has been described in detail, thoseskilled in the art will understand that various changes, substitutions,and alterations herein may be made without departing from the spirit andscope of the invention in its broadest form. The invention is notconsidered limited to the example chosen for purposes of disclosure, andcovers all changes and modifications which do not constitute departuresfrom the true spirit and scope of this invention.

Having thus described the invention, what is desired to be protected byLetters Patent is presented in the subsequent appended claims.

1. A preformed modularized structural header for creating anarchitectural fa£ade during framing said header comprising: (i) anelongated steel beam comprising a web portion and at least one flangeportion being substantially encased in an enclosure; (ii) said enclosurecomprising; a first vertical member having an architecturally pleasingform; a second vertical member spaced from and substantially parallel tosaid first vertical member and the second vertical member having asubstantially matching form to the first vertical member; said verticalmembers having an elongated edge being oriented with respect to saidflange portion of said beam and being in connection with a firsthorizontal member; the first horizontal member and a second horizontalmember spaced from and substantially parallel to said first horizontalmember; at least one of said horizontal members being oriented withrespect to the flange portion of said beam; said vertical members andsaid horizontal members arranged such that said vertical members andsaid horizontal members are rigidly connected in a predetermined wayalong the elongated edges so as to form an enclosure for encasing thebeam with the vertical members forming an architectural façade.
 2. Apreformed modularized structural header in accordance with claim 1wherein the architectural design of said vertical members comprise atleast one of; curved, polygon, round, horseshoe, lancet, ogee, trefoil,basket handle and Tudor.
 3. A preformed modularized structural header inaccordance with claim 2 wherein a void is formed between the web portionof the beam and the vertical members, said void being filled with aninsulating material at least one of: rock wool, fiberglass, Styrofoam,or polyurethane foam.
 4. A preformed modularized structural header inaccordance with claim 3 wherein said insulating material comprises: opencell, low density, non-ozone depleting polyurethane foam.
 5. A preformedmodularized structural header in accordance with claim 3 wherein saidbeam has an insulating value of approximately R20.
 6. A preformedmodularized structural header in accordance with claim 3 wherein saidbeam comprises two flange portions being arranged on substantiallyopposite sides of the web portion.
 7. A preformed modularized structuralheader in accordance with claim 8 wherein the flange portion isconnected with said horizontal members such that said flange portionsubstantially deflects forces created by expanding the insulatingmaterial.
 8. A preformed modularized structural header in accordancewith claim 8 wherein said vertical members interact with said flangeportion to provide support to the vertical member.
 9. A preformedmodularized structural header in accordance with claim 10 wherein saidvertical members further comprises at least one of; a cleat, a shelf, aprojection, a ledge, a sill, a step, or a ridge.
 10. A preformedmodularized structural header in accordance with claim 9 wherein saidrigid connection comprises at least one of: dado's, rabbets, lockjoints, spline joints, tongue and groove, or mortise and tenon joinery.11. A method for making a preformed modular header having anarchitectural façade comprising the steps of; (i) providing an elongatedmetal beam comprising a web portion rigidly connected with a pluralityof flange portions; (ii) encasing the metal beam with an enclosurecomprising; a plurality of matching vertical members having anarchitecturally pleasing form; a first and a second elongated horizontalmembers; said vertical members having an elongated edge, said first andsecond elongated horizontal members each having a plurality of elongatededges; said elongated edge of the vertical members being securelyconnected with said elongated edges of the elongated horizontal membersin a predetermined fashion to substantially form a tight fit with theelongated metal beam such that a void is formed between the web portionof the beam and the vertical members; (iii) filling the void withinsulation.
 12. The method for making a preformed modular header inaccordance with claim 13 wherein the wherein the elongated orthogonalenclosure further comprises a modular arch.
 13. The method for making apreformed modular header in accordance with claim 13 wherein theconnection between the vertical edges and the horizontal edges comprisesat least one of: fasteners, nails, screws, staples, dados, rabbets, lockjoints, spline joints, tongue and groove or mortise and tenon.
 14. Themethod for making a preformed modular header in accordance with claim 13wherein the insulation comprises open cell polyurethane foam.
 15. Themethod for making a preformed modular header in accordance with claim 13wherein vertical member comprises the at least one of; a cleat, a shelf,a projection, a ledge, a sill, a step, or a ridge for engaging with theflange portion of the beam.
 16. A preformed modularized structuralheader for forming header structures for framing said beam comprising:(i) a steel beam comprising a web portion and a plurality of flangeportions; (ii) a substantially wooden box like structure substantiallyenclosing the steel beam comprising; a first vertical member; a secondvertical member spaced from and substantially parallel to said firstvertical member; said vertical members comprising a plurality ofinjection points at predetermined intervals along the members forreceiving an insulating material, each said first and said secondvertical member comprising a cleat; each said first and said secondvertical members further comprising a first and second elongated edgesand; a first horizontal member; a second horizontal member spaced fromand substantially parallel to said first horizontal member; said firstand second horizontal members further comprising a first and a secondelongated edges and; said vertical members and said horizontal membersarranged such that said vertical members and said horizontal members arerigidly connected in a predetermined way along the elongated edges so asto form an elongated orthogonal enclosure having a void, (iii) theelongated orthogonal structure substantially fitting with the steel beamsuch that the flange portions interact with the vertical members toprovide support to the vertical members, a foam insulating materialbeing added through said injection points in such a way as tosubstantially fill said void with the insulating material.